Plasma reactor with plasma load impedance tuning for engineered transients by synchronized modulation of a source power or bias power RF generator

ABSTRACT

In a plasma reactor employing source and bias RF power generators, plasma is stabilized against an engineered transient in the output of either the source or bias power generator by a compensating modulation in the other generator.

BACKGROUND

Plasma processes employed in semiconductor fabrication are constantlybeing improved in order to make smaller device feature sizes in thinfilm structures on semiconductor wafers. Currently, feature sizes are inthe range of tens of nanometers. The ever decreasing feature sizes aredifficult to realize without improvements to various plasma processesused for semiconductor wafers, such as plasma enhanced reactive ionetching, plasma enhanced chemical vapor deposition, plasma enhancedphysical vapor deposition and the like.

SUMMARY

A plasma reactor is provided for processing a workpiece. The reactorincludes plural impedance matches and plural RF plasma power generatorscoupled to deliver respective RF plasma powers into the chamber throughrespective ones of the impedance matches, such as RF plasma source powerand RF plasma bias power, for example. The reactor includes a controllerfor providing a time-varying modulation control signal corresponding toa desired process transient cycle and an amplitude modulator coupled tomodulate the output of a first one of the generators in response to thetime-varying modulation control signal. A stabilization RF powermodulator is coupled to modulate the output of a second one of thegenerators in response to the time-varying modulation control signal.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the exemplary embodiments of the presentinvention are attained and can be understood in detail, a moreparticular description of the invention, briefly summarized above, maybe had by reference to the embodiments thereof which are illustrated inthe appended drawings. It is to be appreciated that certain well knownprocesses are not discussed herein in order to not obscure theinvention.

FIGS. 1A and 1B depict embodiments employing a stabilization RF powergenerator to compensate for engineered transients in the RF plasmasource power generator.

FIGS. 2A through 2F are contemporaneous time domain waveforms depictingoperation of the embodiment of FIG. 1A.

FIGS. 3A through 3C depict embodiments in which stabilization RF poweris applied to a ceiling electrode.

FIGS. 4A through 4D depict embodiments in which stabilization RF poweris obtained by modulating an existing bias power generator.

FIGS. 5A through 5H are contemporaneous time domain waveforms depictingoperation of the embodiment of FIG. 4B.

FIGS. 6A, 6B, 7A and 7B depict embodiments in which an engineeredtransient is obtained by modulating the plasma RF bias power and astabilization RF power generator is employed.

FIGS. 8A through 8F are contemporaneous time domain waveforms depictingoperation of the embodiment of FIG. 6A.

FIGS. 9A and 9B depict embodiments in which stabilization RF power isobtained by modulating the plasma source power generator output.

FIG. 10 depicts an embodiment employing a pair of stabilization RF powergenerators operated in push-pull or out-of-phase relationship.

FIGS. 11A through 11G are contemporaneous time domain waveformsdepicting operation of the embodiment of FIG. 10.

FIGS. 12A and 12B depict embodiments employing an array of pluralstabilization RF power generators with plural sources of engineeredtransients.

FIG. 13 depicts the operation of an optional reflected power feedbackcontrol loop in the foregoing embodiments.

FIG. 14 depicts one embodiment of the synchronizer follower that can beused in the foregoing embodiments.

FIGS. 15A through 15F are contemporaneous time domain waveformsdepicting operation of the embodiment of FIG. 1A with the synchronizerfollower of FIG. 14.

FIGS. 16A through 16H are contemporaneous time domain waveformsdepicting operation of the embodiment of FIG. 4B with the synchronizerfollower of FIG. 14.

FIGS. 17A through 17F are contemporaneous time domain waveformsdepicting operation of the embodiment of FIG. 6A with the synchronizerfollower of FIG. 14.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements and features of oneembodiment may be beneficially incorporated in other embodiments withoutfurther recitation. It is to be noted, however, that the appendeddrawings illustrate only exemplary embodiments of this invention and aretherefore not to be considered limiting of its scope, for the inventionmay admit to other equally effective embodiments.

DETAILED DESCRIPTION

Improvements in plasma processing of workpieces or wafers have recentlybeen found by introducing into the plasma processing recipe certain fastchanges in plasma conditions (transients) at frequencies as high as 100kHz. Such fast changes may be referred to as user-induced transients orengineered transients or scheduled perturbations. One example of such atransient is the pulsing or pulse modulation of plasma source power at apulse repetition rate between 0.1 Hz and 100 kHz. Such pulsing of theplasma source power induces contemporaneous changes in plasma loadimpedance.

Such changes or transients are automatically followed by the RFimpedance match element, so that power reflected back to the RFgenerator(s) is minimized or remains at an acceptable level. The actionof the RF impedance match element in maintaining a constant impedancematch for the RF generator is necessary for two reasons. First, themeasurement and control of RF power delivered to the plasma must besufficiently accurate to carry out requirements of the process recipe.Secondly, the RF generator must be protected from damage by reflected RFpower (which is caused by an impedance mismatch between the RF generatoroutput and the plasma).

As the pulse rate is increased toward 100 kHz, each RF impedance matchelement begins to have difficulty following the rapid plasma impedancechanges, until, at some threshold frequency near 100 kHz, the impedancematch element ceases to function, and provides an impedance mismatch.Upon this occurrence, the power reflected back to the RF generatorexceeds an acceptable level, and the reactor is shut down. It has notseemed possible to introduce engineered transients at or near 50-100 kHzor above.

The inability of the impedance match element to follow the higherfrequency transients may be attributable to its design. For impedancematch elements employing variable reactance elements, the variablereactance elements may have mechanical limitations that slow theirresponse, and typically have response times on the order of one second.For impedance match elements employing tuned frequency generators, thefrequency tuning element of such a device may have mechanicallimitations that slow their response, and typically have response timeson the order of 100 milliseconds. These limitations are inherent in RFimpedance match elements, so that it has not seemed possible tostabilize plasma impedance against transients at 50-100 kHz.

Plasma or plasma impedance is stabilized in a plasma process againstscheduled perturbations or engineered transients in plasma conditions athigh perturbation rates (e.g., as high as 100 kHz or more) withoutrelying upon the reactor's impedance match elements (e.g., variablereactance impedance matches or frequency tuned impedance matches).Instead, stabilization RF power of a selected frequency is applied tothe plasma and modulated in synchronism with the engineered transient.Such modulation may be referred to as stabilization modulation orstability modulation. The frequency and power level of the stabilizationRF power is such that it opposes the change in plasma impedanceotherwise induced by the engineered transient. Generally, the plasmareactor has an RF plasma source power generator coupled to the reactorthrough an RF impedance match device. It may also have one or more biaspower generators coupled to the wafer support through respectiveimpedance match elements. The engineered transient may take the form ofpulse modulation of the RF plasma source power generator. An engineeredtransient or scheduled perturbation of a chosen one of the RF powergenerators (plasma source power generator or plasma bias powergenerator) may be produced by applying a time-varying modulation controlsignal to a modulator coupled to the output of the chosen RF powergenerator. The time-varying modulation control signal corresponds to thedesired engineered transient or scheduled perturbation, and may beproduced in a controller provided for this purpose. For example, if thedesired engineered transient consists of pulsing of the RF power fromthe chosen RF power generator, then the time-varying modulation controlsignal may be a pulse waveform. The engineered transient is not limitedto pulsed waveforms, but may have any other desired waveform (e.g.,sawtooth, ramped, sinusoidal, and so forth). In some embodiments, thestabilization RF power is obtained from an auxiliary low power RFgenerator (one or more) coupled to the reactor without an impedancematch element. In other embodiments, stabilization RF power is obtainedfrom pre-existing bias power generators or the source power generator.In this case, a selected one (or ones) of the pre-existing generatorsare amplitude modulated in synchronism with the engineered transient.

The selection of the frequency of the stabilization RF power may be madein accordance with the type of fluctuation in plasma impedance expectedto be induced by the engineered transient. For fluctuations in theimaginary component of the plasma impedance (e.g., the capacitance), thestabilization RF power frequency may be an LF frequency that stronglyaffects plasma sheath thickness. For fluctuations in the real componentof the plasma impedance (e.g., the resistance), the stabilization RFpower frequency may be a VHF frequency that strongly affects plasmaelectron density.

As one example, the RF plasma source power generator may be coupled toan overhead electrode of the reactor chamber through an impedance matchelement, and operate at a VHF frequency (e.g., above 50 MHz) forefficient plasma generation. The engineered transient may includepulsing of the VHF power applied to the overhead electrode. Such anengineered transient may have, as its purpose, modulating the plasmaelectron density in order to improve some aspect of a plasma process.Such pulsing of the overhead electrode VHF plasma source power may causethe plasma sheath thickness to fluctuate in synchronism with thepulsing. In one example, the overhead electrode VHF source power ispulsed between high and low power levels, in which case the plasmasheath thickness is minimum during the pulse duration of the high powerlevel. This fluctuation in plasma sheath thickness causes the capacitivecomponent of the plasma impedance to fluctuate in similar manner. If thepulse rise time is low and the pulse repetition rate is high (e.g., near100 kHz), the impedance match element for the VHF plasma source powergenerator cannot follow the changes in plasma impedance. The frequencyof the stabilization RF power (e.g., of the auxiliary RF generator) isselected to oppose any decrease in plasma sheath thickness during eachpulse duration of the high power level. In one embodiment, the auxiliaryRF power generator produces an LF frequency, which is ideal forincreasing the plasma sheath thickness or, in the present case, opposingits decrease during each source power pulse duration. If such anauxiliary RF power generator is employed, then it is synchronized withthe pulse modulation of the engineered transient, and its output iscoupled to the reactor at the wafer support or at the overhead ceiling.

As another example, an RF plasma bias power generator (separate from theRF plasma source power generator) may be coupled to an electrode in thewafer support within the reactor chamber through an impedance matchelement, and operate at an LF frequency (e.g., below 1 MHz) for controlof plasma sheath voltage and ion energy. The engineered transient mayinclude pulsing of the LF power applied to the wafer support electrode.Such an engineered transient may have, as its purpose, the modulating ofthe plasma sheath voltage to improve some aspect of the plasma process.Such pulsing of the wafer support electrode LF plasma bias power maycause the plasma electron density to fluctuate in synchronism with thepulsing. In one example, the LF bias power is pulsed between high andlow power levels, in which case the plasma electron is minimum duringthe pulse duration of the high power level. This fluctuation in plasmaelectron density causes the resistive component of the plasma impedanceto fluctuate in similar manner. If the pulse rise time is low and thepulse repetition rate is high (e.g., near 100 kHz), the impedance matchelements for the source power generator and the bias power generatorcannot follow the changes in plasma impedance. The frequency of thestabilization RF power (e.g., of the auxiliary RF generator) is selectedto oppose any decrease in plasma electron density during each pulseduration of the high power level. In one embodiment, the auxiliary RFpower generator produces a VHF frequency, which is ideal for increasingthe plasma electron density or, in the present case, opposing itsdecrease during each bias power pulse duration. If such an auxiliary RFpower generator is employed, then it is synchronized with the pulsemodulation of the engineered transient, and its output is coupled to thereactor at the overhead ceiling or at the wafer support electrode.

In further embodiments, plural stabilization generators of differentfrequencies coupled to the reactor are synchronized with the engineeredtransient in cases where the engineered transients change more than oneplasma parameter. For example, both an LF stabilization source and an HFor VHF stabilization source may be employed in concert to opposetransient-induced changes in both plasma sheath thickness and in plasmaelectron density. As one example in which the engineered transientincludes pulsing the plasma RF source power between high and low levels,LF stabilization power is applied to the plasma during each high pulseduty cycle in order to oppose a decrease in plasma sheath thicknesscaused by increased source power level. And, VHF stabilization power isapplied to the plasma during each low pulse duty cycle to oppose adecrease in plasma electron density caused by decreased source powerlevel. In this example, the LF and VHF stabilization power waveforms maybe of opposing phases.

FIG. 1A depicts an embodiment in which a plasma process recipe calls forpulsing the plasma source power at a desired pulse rate and pulse width.The reactor in this embodiment includes a reactor chamber 100 having acylindrical side wall 105 which may be a conductor, a workpiece support110 and a ceiling 115 defining a processing volume 120. The ceiling 115includes an electrode 115-1 having a gas distribution showerhead 115-2on its bottom surface fed by a gas supply 125, and an insulating ring115-3 separating the electrode 115-1 from the sidewall 105. Theworkpiece support 110 has a workpiece support surface 110-1 supporting aworkpiece 130 which may be a semiconductor wafer, for example. Theworkpiece support has an electrode 130-1 encapsulated within aninsulating layer that includes an upper insulating layer 130-2 betweenthe electrode 130-1 and the workpiece support surface 110-1 and a lowerinsulating layer 130-3 beneath the electrode 130-1. The lower insulatinglayer 130-3 is supported on a conductive base 130-4. A vacuum pump 140evacuates the chamber 100 through a pumping annulus 145 defined betweenthe workpiece support 110 and the sidewall 105.

Plasma source power is applied to the ceiling electrode 115-1 from a VHFplasma source power generator 150 through a dynamic impedance matchcircuit 155. The desired engineered transient is produced by acontroller 160. Specifically, the controller 160 includes aprocess-enhancing modulation signal generator 161 that generates atime-varying modulation control signal in accordance with the desiredtransient defined by a process recipe selected by the user. A transientmodulator 165 at the output of the VHF plasma source power generator 150modulates the amplitude or power level of the generator output inresponse to the time-varying modulation control signal from the controlsignal generator 161. The action of the transient modulator 165 inresponse to the time-varying modulation control signal from the signalgenerator 161 produces the desired transient in the output of the VHFplasma source power generator 150. FIG. 2A depicts an example in which asingle transient is introduced. The transient may be any sort ofmodulation, such as (for example) ramp modulation, sawtooth modulation,exponential burst modulation or pulse modulation or any transient ormodulation having a Fourier component of at least 10 Hz. In the exampleof FIG. 2A, the transient is a single pulse, although the transient ormodulation may be repeated. If the time-varying modulation controlsignal is a single pulse, then the VHF generator modulator 165 producesthe output power waveform depicted in FIG. 2A. In one example, the VHFplasma source power is pulsed between two power levels P₁ and P₂, asdepicted in FIG. 2A. In another unillustrated example, in which themodulation is repetitive, the duty cycle of the lower power level may belonger than that of the higher power level. As plasma power is increasedduring the high power level duty cycle, the resulting increase in plasmaelectron density depresses the plasma sheath thickness in synchronismwith the pulsed waveform, as depicted in FIG. 2B. This raises thecapacitive component of the plasma impedance in synchronism with thepulse waveform. If the pulse repetition rate is too fast for theimpedance match to follow, the sudden changes in plasma impedance causean impedance mismatch and consequent increase in power reflected back tothe VHF generator 150 in synchronism with the pulsed waveform, asdepicted in FIG. 2C.

In order to avoid an increase in reflected source power, a low powerauxiliary or stabilization RF generator 170 is coupled to the chamber100, specifically to the wafer support electrode 130-1, through afollower modulator 175. No impedance match is provided for thestabilization generator 170, since its purpose is to respond to atransient whose speed is beyond the capability of an impedance matchcircuit. The controller 160 includes a synchronizer or follower 162 thatgenerates a stabilization control signal controlling the followermodulator 175 in response to the output of the control signal generator161. The stabilization control signal from the follower 162 isresponsive to the time-varying modulation control signal from thegenerator 161. In one simplified embodiment, the two control signals maybe the same signal. The follower modulator 175 produces a pulsed RFwaveform depicted in FIG. 2D. In one embodiment, the RF frequency of thestabilization power generator 170 is a low frequency or very lowfrequency that strongly influences the plasma sheath thickness, so as tooppose its reduction during each pulse duty cycle of the source power.The result is that the plasma sheath thickness reduction during eachpulse duty cycle is greatly reduced, as depicted in FIG. 2E, whichreduces the change in plasma capacitance and thereby reduces theimpedance mismatch and the VHF power reflected back to the VHF generator150, as depicted in FIG. 2F.

The frequency of the stabilization RF power generator 170 is selected tobe sufficiently low (e.g., from several MHz to as low as a several kHz)to efficiently change plasma sheath thickness. At such a low frequency,the power level of the stabilization RF generator 170 may be a fractionof the power level of the source power generator 150, and depends atleast in part upon the degree of modulation of the source power by themodulator 165. In one example, if the proportion between the high andlow source power levels P₂ and P₁ of FIG. 2A is about 50%, and if P₁ isseveral kilowatts, only several hundred Watts may be required from thestabilization RF generator 170 to adequately reduce reflected power. Atan optimum modulation or amplitude level of the stabilization RF powergenerator 170, the change in plasma impedance associated with each cycleof the engineered transient is minimized or nullified, so that plasmaload impedance changes very little if at all. This optimum power levelor degree of modulation of the stabilization RF power generator 170 canbe determined by trial and error for the chosen engineered transient, orcan be optimized in a feedback control loop described later in thisspecification.

As depicted in dashed line in FIG. 1A, the reactor optionally mayfurther include one or more RF plasma bias power generators 180, 185coupled to the wafer support electrode 130-1 through respectiveimpedance matches 190, 195. The two bias power generators may havedifferent frequencies suitable for adjusting the electron energydistribution function at the surface of the workpiece. For example, thebias power generator 180 may be an LF power generator while the biaspower generator 185 may be an VLF or HF power generator. The reflectedpower at each of the bias generators 180, 185 may be improved by usingthe stabilization power generator 170 in a manner similar to thatdiscussed above with reference to FIGS. 2A through 2F. As employed inthis specification, VHF refers to frequencies in a range of 30-300 MHzand HF refers to frequencies in a range of 3-30 MHz. As used in thisspecification, LF refers to both middle frequencies (300 kHz to 3 MHz)and low frequencies (30-300 kHz), and VLF refers to frequencies below 30kHz. In general, in the upper portion of the VHF range (e.g., above 150MHz), 80% or more of the RF power contributes to plasma electrongeneration or plasma electron density. In the lower portion of the LFrange defined above (e.g., below 2 MHz), 80% or more of the RF powercontributes to plasma sheath thickness or sheath voltage.

FIG. 1B depicts a modification of the embodiment of FIG. 1A, in whichthe overhead electrode 115-1 is replaced by a dielectric ceiling 115-4,and an inductive coil antenna 197 receives the RF source power from thegenerator 150 through the impedance match 155. The plasma is generatedby inductive coupling, in which case the frequency of the source powergenerator 150 may be in the HF or LF range rather than VHF. However,modulation of the LF or HF source power applied to the coil antenna 197in the inductively coupled plasma source of FIG. 1B has essentially thesame effect as modulation of the VHF power in the capacitively coupledreactor of FIG. 1A. The stabilization generator 170 operates in the samemanner in the reactor of FIG. 1B as in the reactor of FIG. 1A to reducereflected RF power.

FIG. 3A depicts an embodiment in which the output of the stabilizationgenerator 170 and modulator 175 are applied to the ceiling electrode115-1 rather than the wafer support electrode 130-1.

FIG. 3B depicts a similar embodiment, but in which the dynamic impedancematch 155 has been replaced by a fixed impedance match element, such asa coaxial tuning stub 200. The coaxial tuning stub 200 has coaxialhollow inner and outer conductors 201, 202, the inner conductor 201being coupled to the ceiling electrode 115-1 through a conductive ring203, and the outer conductor 202 being coupled to the chamber sidewall105 through conductive rings 204, 205. A conductor disk 206 at the farend of the coaxial stub 200 shorts the inner and outer conductors 201,202 together. The VHF source power generator 150 is connected across theinner and outer coaxial conductors at a predetermined location along thelength of the coaxial tuning stub 200. The gas supply 125 is connectedvia conduits to the gas distribution showerhead 115-2 through the hollowinterior of the inner conductor 201. In this embodiment, thestabilization power generator 170 reduces RF power reflected back to thebias power generators 180, 185.

FIG. 3C depicts a modification of the reactor of FIG. 3A, in which theoverhead electrode 115-1 is replaced by a dielectric ceiling 115-4, andan inductive coil antenna 197 overlying the ceiling 115 receives the RFsource power from the generator 150 through the impedance match 155. Theplasma is generated by inductive coupling, in which case the frequencyof the source power generator 150 may be in the HF or LF range ratherthan VHF. The output of the stabilization power generator 170 and itsmodulator 175 may be coupled directly to the coil antenna 197, asdepicted in the drawing, in which case the stabilization power generator170 may be an HF or LF generator to have the desired effect upon plasmaelectron density. Alternatively, the ceiling 115 may include an overheadelectrode (not shown) that is nearly transparent to the coil antenna197, such as a Faraday shield for example, and the stabilizationgenerator modulator 175 is connected to this overhead electrode. In thisalternative case, the frequency of the stabilization generator 170 is aVHF frequency in order to affect plasma electron density throughcapacitive coupling.

FIG. 4A depicts an embodiment in which stabilization power is providedby modulating power from a pre-existing bias power generator. Thisobviates the need to provide a dedicated stabilization RF powergenerator, such as the stabilization power generator 170 of FIG. 1A. Inthe embodiment of FIG. 4A, the reactor includes an RF bias powergenerator 220 (which may be a high power RF generator) coupled to theworkpiece support electrode 130-1 through an impedance match circuit225. In the embodiment of FIG. 4A, the modulator 175 controls the outputof the bias power generator 220 in such a way as to stabilize the plasmaimpedance against the engineered transients in the source power. In oneexample, the modulator 175 may impose less than 100% modulation of theRF bias power. Modulation of the bias power generator 220 in FIG. 4Aoutput may have the same effect as the provision of the stabilizationpower generator 170 in FIG. 1. The bias power generator 220 may producevery high power level (e.g., in the range of kilowatts), and thereforethe desired stabilization effect may be obtained by only a smallmodulation (e.g., 5%) of the output of the bias power generator 220.

FIG. 4B depicts a modification of the reactor of FIG. 4A, in which thereare plural RF bias power generators of different frequencies coupled tothe wafer support electrode 130-1, which is a feature useful forselecting the ion energy distribution function. In the illustratedembodiment, there are two bias power generators, 180, 185, coupled tothe wafer support electrode 130-1 through respective impedance matchcircuits 190, 195. The RF bias generators 180, 185 may for example be LFand HF generators, respectively. One of the two generators 180, 185 isselected to supply the stabilization RF power, which in the illustratedexample is the LF bias power generator 180. In the embodiment of FIG.4B, the modulator 175 is coupled to the output of the LF bias powergenerator 180, and imposes a modulation (e.g., pulse modulation) of theRF power output of the generator 180 for RF power stabilization of theplasma impedance. In one example, the modulator 175 of FIG. 4B mayimpose less than 100% modulation of the RF bias power. Modulation of thebias power generator 180 in FIG. 4B output may have the same effect asthe provision of the stabilization power generator 170 in FIG. 1A. Thebias power generator 180 may produce a very high power level (e.g., inthe range of kilowatts), and therefore the desired stabilization effectmay be obtained by only a small modulation (e.g., 5%) of the output ofthe bias power generator 180.

FIG. 5A depicts the time domain waveform of the output of the sourcepower generator 150 in the reactor of FIG. 4B. The pulsed shape of thiswaveform corresponds to a desired engineered transient produced by thecontroller 160 and source power modulator 165. FIG. 5A depicts anexample in which a single transient is introduced. The transient may beany sort of modulation, such as (for example) ramp modulation, sawtoothmodulation, exponential burst modulation or pulse modulation or anytransient or modulation having a Fourier component of at least 10 Hz. Inthe example of FIG. 5A, the transient is a single pulse, although thetransient or modulation may be repeated. FIG. 5B depicts the behavior ofthe plasma sheath thickness responsive to the engineered transient insource power. FIGS. 5C and 5D depict the large excursions in RF powerreflected back to the source power generator 150 and to the bias powergenerator 190, respectively, in the absence of any stabilization. FIG.5E depicts the output of the bias power generator 180 as modulated bythe modulator 175 as a stabilizing influence upon plasma impedance and acountervailing influence against impedance fluctuations due to theengineered transient. As shown in FIG. 5E, stabilization is attained bymodulating the bias power between two power levels, P₃ and P₄. Thechange between these two power levels may correspond to 5-10%modulation, for example. FIG. 5F depicts the reduced fluctuation inplasma sheath thickness obtained with the stabilizing modulation of thebias power depicted in FIG. 5E. FIGS. 5G and 5H depict the reducedfluctuations in RF power reflected back to the source power generator150 and to the bias power generator 190, respectively, obtained with thepower stabilization of the plasma impedance.

FIG. 4C depicts a modification of the reactor of FIG. 4B in which thedynamic impedance match 155 has been replaced by a fixed impedance matchelement, such as the coaxial tuning stub 200 of FIG. 3B, which isdescribed above.

FIG. 4D depicts another modification of the reactor of FIG. 4B, in whichthe overhead electrode 115-1 is replaced by a dielectric ceiling 115-4,and an inductive coil antenna 197 overlying the ceiling 115 receives theRF source power from the generator 150 through the impedance match 155.The plasma is generated by inductive coupling, in which case thefrequency of the source power generator 150 may be in the HF or LF rangerather than VHF. However, modulation of the LF or HF source powerapplied to the coil antenna 197 in the inductively coupled plasma sourceof FIG. 4D has essentially the same effect as modulation of the VHFpower in the capacitively coupled reactor of FIG. 1A. The primary effectis to create the desired engineered transient (e.g., pulsed sourcepower) that improves an aspect of the plasma process. A secondary butundesired effect is to change plasma impedance faster than thecapability of the impedance match (e.g., the impedance match 155 or 190or 195), so that an impedance mismatch arises which increases reflectedRF power (to one or more of the generators 150, 180, 185) tounacceptable levels. The modulation of the output of the RF bias powergenerator 180 produces the desired stabilization of the plasma impedance(by opposing changes in the plasma sheath thickness). This reducesreflected RF power caused by the engineered transient.

The foregoing embodiments included examples in which the engineeredtransient was obtained by modulating (e.g., pulse-modulating) the RFplasma source power generator 150. In other processes, however, thedesired engineered transient may be obtained by modulating an RF plasmabias power generator rather than the plasma source power. One reactor ofthis type of embodiment is depicted in FIG. 6A, which is a modificationof the embodiment of FIG. 4A. In the reactor of FIG. 6A, the modulator165 (controlled by the process enhancing modulation signal generator161) is coupled to the output of the RF plasma bias power generator 220to produce the engineered transient in RF bias power. Plasma isgenerated, as in other embodiments herein, by the VHF source powergenerator 150 driving the ceiling electrode 115-1 through the impedancematch 155. The impedance match 155 may be either a dynamic impedancematch (e.g., a variable reactance-tuned impedance match or afrequency-tuned impedance match) or a fixed impedance match. Theengineered transient may, for example, involve any degree of modulationof the bias power, up to and including 100% modulation (in which thebias power is pulsed on and off) or a modest degree of modulation (inwhich the bias power is pulsed between two different power levels). Thedegree of modulation is determined by the controller 160 in accordancewith a predetermined process recipe.

In the reactor of FIG. 6A, the plasma impedance is stabilized againstfluctuations induced by the engineered transient. The stabilization RFpower generator 170 is coupled through the modulator 175 to the wafersupport electrode 130-1 without an impedance match between thestabilization generator 170 and the wafer support electrode 130-1. TheRF bias power generator 220 is, typically, either an LF generator (e.g.,having a frequency in the kHz range or a few MHz) or an HF generator(e.g., having a frequency from several MHz up to about 30 MHz). Theengineered transient (e.g., pulsing) of the RF bias power has theprimary effect of changing the plasma sheath thickness. It has asecondary effect of changing the plasma electron density, dropping thedensity with each pulse in bias power. In order to oppose such drops inplasma density, the stabilization RF power generator 170 has VHFfrequency (or a frequency that is highly efficient in generating plasmaelectrons). If the transient modulator 165 imposes pulse modulation onthe bias power generator 220, then the follower modulator 175 imposes acorresponding pulse modulation of the stabilization RF power generator170. The pulsed output of the stabilization RF power generator 170opposes reduction in the plasma sheath thickness that would be caused bythe pulsing of the bias power generator 220. The plasma sheath thicknessfluctuations are thereby reduced, which reduces impedance mismatchingbetween the plasma and the source power generator 150.

FIG. 6B depicts a modification of the reactor of FIG. 6A, in which theoverhead electrode 115-1 is replaced by a dielectric ceiling 115-4, andan inductive coil antenna 197 overlying the ceiling 115 receives the RFsource power from the generator 150 through the impedance match 155. Theplasma is generated by inductive coupling, in which case the frequencyof the source power generator 150 may be in the HF or LF range ratherthan VHF.

FIG. 7A depicts a modification of the reactor of FIG. 6A in which theoutput of the stabilization RF power generator 170 and modulator 175 iscoupled to the ceiling electrode, without an intervening impedance matchelement, rather than being coupled to the wafer support electrode 130-1.

FIG. 7B depicts a modification of the reactor of FIG. 7A, in which theoverhead electrode 115-1 is replaced by a dielectric ceiling 115-4, andan inductive coil antenna 197 overlying the ceiling 115 receives the RFsource power from the generator 150 through the impedance match 155. Theplasma is generated by inductive coupling, in which case the frequencyof the source power generator 150 may be in the HF or LF range ratherthan VHF. The output of the stabilization power generator 170 and itsmodulator 175 may be coupled directly to the coil antenna 197, asdepicted in the drawing, in which case the stabilization power generator170 may be an HF or LF generator to have the desired effect upon plasmaelectron density. Alternatively, the ceiling 115 may include an overheadelectrode (not shown) that is nearly transparent to the coil antenna197, such as a Faraday shield for example. In this alternative case, thefrequency of the stabilization generator 170 is a VHF frequency in orderto affect plasma electron density through capacitive coupling.

Operation of the reactor of FIG. 6A is depicted in the contemporaneouswaveform diagrams of FIGS. 8A-8F. FIG. 8A depicts the time domainwaveform of the output of the bias generator 220 as modulated by themodulator 165 in an example in which a single transient is introduced inthe bias power. The transient may be any sort of modulation, such as(for example) ramp modulation, sawtooth modulation, exponential burstmodulation or pulse modulation or any transient or modulation having aFourier component of at least 10 Hz. In the example of FIG. 8A, thetransient is modulation by a single pulse, although the transient ormodulation may be repeated. FIG. 8B depicts the corresponding behaviorof the plasma electron density, which drops with the pulse increase ofthe bias power. FIG. 8C depicts the resulting fluctuation in RF powerreflected back to the source power generator 150 as a result of thechanges in the resistive component of the plasma impedance the followthe fluctuations in plasma electron density. The behavior depicted inFIGS. 8B and 8C is in the absence of any impedance stabilization RFpower from the generator 170 and modulator 175. FIG. 8D depicts thepower envelope of the output of the VHF stabilization power generator170 and modulator 175. The pulsed VHF power from the generator 170opposes drops in plasma electron density occurring with each pulse ofthe bias power. FIG. 8E depicts the reduced fluctuation in electrondensity as a result of the power from the stabilization power generator170. FIG. 8F depicts the RF power reflected back to the source powergenerator 150, the reflected power having been greatly reduced by thestabilization of the plasma electron density and plasma impedance.

FIG. 9A depicts a modification of the reactor of FIG. 7A, in which theplasma electron density is stabilized against the engineered transientsin the RF bias power without providing a separate stabilization RF powergenerator. Instead, stabilization is attained by modulating the VHFsource power generator 150, using a low degree (e.g., 5%) of modulation.As shown in the drawing of FIG. 9A, the stabilization modulator 175 isinterposed between the VHF source power generator 150 and the VHFimpedance match 155.

FIG. 9B depicts a modification of the reactor of FIG. 9A, in which theoverhead electrode 115-1 is replaced by a dielectric ceiling 115-4, andan inductive coil antenna 197 overlying the ceiling 115 receives the RFsource power from the generator 150 through the impedance match 155. Theplasma is generated by inductive coupling, in which case the frequencyof the source power generator 150 may be in the HF or LF range ratherthan VHF.

In some embodiments, different fluctuations in plasma impedance arecompensated during different phases of the engineered transient. Forexample, if the engineered transient includes pulse modulating the VHFbias power generator, then during the pulse “on” time a decrease inplasma sheath thickness is compensated, while during the pulse “off”time a decrease in plasma electron density is compensated. This requirestwo stabilization RF power generators, namely a LF or VLF powergenerator active during the pulse “on” time for opposing a decrease inplasma sheath thickness, and a VHF power generator for opposing a dropin plasma electron density during the pulse “off” time. A reactor havingthis capability is depicted in FIG. 10. The reactor of FIG. 10 is amodification of the reactor of FIG. 1A. In this modification, there aretwo stabilization RF power generators including a VHF stabilizationgenerator 170 a and an LF or VLF stabilization generator 170 b withrespective modulators 175 a, 175 b at their outputs and coupled to thewafer support electrode 130-1. Furthermore, the synchronization follower162 produces separate control signals to the modulators 175 a, 175 bthat cause the output of the two stabilization generators 170 a, 170 bto have different phases and (if desired) different amplitudes. In thepresent example, the outputs of the two generators 175 a, 175 b are outof phase.

Operation of the embodiment of the reactor of FIG. 10 is described withreference to FIGS. 11A through 11G. FIG. 11A illustrates the pulsedmodulation of the VHF source power. FIG. 11A depicts an example in whicha single transient is introduced. The transient may be any sort ofmodulation, such as (for example) ramp modulation, sawtooth modulation,exponential burst modulation or pulse modulation or any transient ormodulation having a Fourier component of at least 10 Hz. In the exampleof FIG. 11A, the transient is a single pulse, although the transient ormodulation may be repeated. FIGS. 11B and 11C depict the correspondingbehavior of the plasma sheath thickness and the plasma electron density,respectively, in the absence of stabilization. FIG. 11D depicts theoutput of the LF or VLF stabilization generator 170 b and FIG. 11Edepicts the resulting reduced fluctuations in the plasma sheaththickness. FIG. 11F depicts the output of the VHF stabilizationgenerator and FIG. 11G depicts the resulting reduced fluctuations inplasma electron density.

Various configurations of multiple independent stabilization RF powergenerators are possible. FIG. 12A depicts a plasma reactor having anarray of stabilization generators 170 a, 170 b, 170 c coupled throughrespective modulators 175 a, 175 b, 175 c to the overhead electrode115-1, and an array of stabilization generators 170 d, 170 e, 170 fcoupled to the wafer support electrode 130-1 through respectivemodulators 175 d, 175 e, 175 f. In addition, the outputs of the sourcepower generator 150, the bias power generator 180 and the bias powergenerator 185 can be modulated by respective modulators 165 a, 165 b,165 c by independent control signals (labeled A, B and C in FIG. 10A)produced by the process enhancing modulation signal generator 161.Control signal A modulates the VHF source power when activated. Itfurther controls, through respective synchronization followers 162 a,162 d, the outputs of the stabilization generators 170 a, 170 d, ifactivated, whose frequencies are selected to effectively compensate fortransients in the VHF power. Control signal B modulates the HF biaspower when activated. It further controls, through respectivesynchronization followers 162 b, 162 e, the outputs of the stabilizationgenerators 170 b, 170 e, if activated, whose frequencies are selected toeffectively compensate for transients in the HF bias power. Controlsignal C modulates the LF bias power when activated. It furthercontrols, through respective synchronization followers 162 c, 162 f, theoutputs of the stabilization generators 170 c, 170 f, if activated,whose frequencies are selected to effectively compensate for transientsin the LF bias power. The responses of the various synchronizationfollowers 162 a through 162 f may be in phase, out of phase,asynchronous or synchronous, push-pull, etc., to achieve the desiredplasma impedance stabilization.

FIG. 12B depicts a modification of the reactor of FIG. 12A, in which theoverhead electrode 115-1 is replaced by a dielectric ceiling 115-4, andan inductive coil antenna 197 overlying the ceiling 115 receives the RFsource power from the generator 150 through the impedance match 155. Theplasma is generated by inductive coupling, in which case the frequencyof the source power generator 150 may be in the HF or LF range ratherthan VHF.

The modulation of the stabilization RF power may be controlled in realtime to minimize reflected RF power sensed in real time at the sourcepower generator (or at any bias power generator). For example, in FIG.1A, reflected RF power sensed at the source power generator 150 (usingconventional techniques) relative to delivered (or total) RF power isfurnished to the controller 160 as feedback signal at a reflected powersensor output 300 from the source power generator 150 in the foregoingembodiments. Alternatively, the reflected power sensor output may befrom one of the RF bias power generators 180, 185. The controller 160adjusts the degree of modulation of the stabilization power generator170 (e.g., between 0% and 100% modulation) to minimize the reflectedpower. The controller 160 may be programmed with a trial-by-erroralgorithm, in which the controller 160 performs many processor cyclesduring each transient or pulse duration. In each processor cycle, thecontroller 160 determines whether the reflected power has increasedsince the previous processor cycle, and meets an increase in reflectedpower during the subsequent processor cycles by determining whether anincrease or decrease in modulation of the stabilization generator outputdecreases the sensed reflected power during the next processor cycle. Asuccessful trial leads the processor 160 to repeat whatever actionpreceded that success, i.e., either an increase or decrease in degree ofmodulation. The various embodiments illustrated in the drawingsdiscussed above are illustrated as having the feature of the feedbackinput 300 of sensed reflected power from the source power generator 150(FIGS. 1, 3A-3C, 4A-4D) and/or from a bias power generator 180 or 185(FIGS. 6A-6B, 7A-7B and 9A-9B).

One example of the operation of such a feedback loop by the controller160 is depicted in FIG. 11 during a single processor cycle which is oneof a succession of processor cycles. The first step (block 310) is tosense the reflected RF power at the source power generator 150 or biaspower generator (180 or 185) of interest. The controller 160 thendetermines whether the reflected RF power has decreased or increasedsince the last processor cycle (block 320 of FIG. 11). If it hasdecreased (block 325), the prior change (if any) made to thestabilization power modulation (either a decrease or an increase inmodulation percentage) is repeated (block 330). Such a change is apredetermined shift in the modulation percentage (e.g., by ±1%).Otherwise, if the reflected power has increased (block 335), the priorchange made is reversed (block 340). This completes the currentprocessor cycle, and the controller goes to the next processor cycle(block 350) and repeats the foregoing.

The plasma capacitance and resistance combines to change the plasmaresponse to the sharp edges of the engineered transient so that it doesnot conform with the square edges, for example of pulse modulated sourcepower. The near instantaneous rise time of the edge of the plasma sourcepower pulse modulation of FIGS. 1A and 2A (for example) induce aresponse in the plasma impedance having much longer rise times andsmooth transitions without sharp edges. Therefore, a more accuratestabilization of plasma impedance requires the response of thestabilization RF power generator 170 (as determined by its modulator175) to mimic the more gradual rise times and smoothed edges of theplasma response. Such an accurate response is obtained using theembodiment of the synchronizer follower 162 of FIG. 14. The synchronizerfollower 162 of FIG. 14 conditions the signal (e.g., a pulse signal)from the process enhancing modulation signal generator 161. First, theamplitude is adjusted by an amplitude adjustment circuit 162-1. Theresponse is delayed by a delay circuit 162-2. The response is shaped bya waveform shaping circuit 162-3. The waveform shaping circuit 162-3 incombination with the delay circuit 162-2 reproduces the R-Ccharacteristics of the plasma response.

FIGS. 15A-15F depict the operation of the reactor of FIG. 1 using thesynchronizer follower 162 of FIG. 14. FIG. 15A depicts the sharp pulsemodulation of the source power. FIG. 15A depicts an example in which asingle transient is introduced. The transient may be any sort ofmodulation, such as (for example) ramp modulation, sawtooth modulation,exponential burst modulation or pulse modulation or any transient ormodulation having a Fourier component of at least 10 Hz. In the exampleof FIG. 15A, the transient is a single pulse, although the transient ormodulation may be repeated. FIG. 15B depicts the response of the plasmasheath thickness having delayed exponential leading and trailing edges,in accordance with an R-C time constant of the plasma. FIG. 15C depictsthe reflected power at the source power generator in the absence ofstabilization. FIG. 15D depicts the waveform of the stabilization RFpower obtained using the synchronization follower 162 of the embodimentof FIG. 14, which more accurately follows the exponential response ofthe plasma sheath thickness of FIG. 15B. FIGS. 15E and 15F depict thereduced fluctuations in plasma sheath thickness and reflected powerobtained using the stabilization RF power of FIG. 15D.

FIGS. 16A-16H depict the operation of the reactor of FIG. 4B using thesynchronizer follower 162 of FIG. 14. FIG. 16A depicts the sharp pulsemodulation of the source power. FIG. 16A depicts an example in which asingle transient is introduced. The transient may be any sort ofmodulation, such as (for example) ramp modulation, sawtooth modulation,exponential burst modulation or pulse modulation or any transient ormodulation having a Fourier component of at least 10 Hz. In the exampleof FIG. 16A, the transient is a single pulse, although the transient ormodulation may be repeated. FIG. 16B depicts the response of the plasmasheath thickness having delayed exponential leading and trailing edges,in accordance with an R-C time constant of the plasma. FIGS. 16C and 16Ddepict the reflected power at the source power generator and at a biaspower generator, respectively, in the absence of stabilization. FIG. 16Edepicts the waveform of the stabilization RF power obtained using thesynchronization follower 162 of the embodiment of FIG. 14, which moreaccurately follows the exponential response of the plasma sheaththickness of FIG. 16B. FIG. 16F depict the reduced fluctuations inplasma sheath thickness obtained using the stabilization RF power ofFIG. 16E. FIGS. 16G and 16H depict the reduced fluctuations in reflectedpower at the source power generator and the bias power generator,respectively.

FIGS. 17A-16F depict the operation of the reactor of FIG. 6A using thesynchronizer follower 162 of FIG. 14. FIG. 17A depicts the sharp pulsemodulation of the source power. FIG. 17A depicts an example in which asingle transient is introduced. The transient may be any sort ofmodulation, such as (for example) ramp modulation, sawtooth modulation,exponential burst modulation or pulse modulation or any transient ormodulation having a Fourier component of at least 10 Hz. In the exampleof FIG. 17A, the transient is a single pulse, although the transient ormodulation may be repeated. FIG. 17B depicts the response of the plasmaelectron density having delayed exponential leading and trailing edges,in accordance with an R-C time constant of the plasma. FIG. 17C depictsthe reflected power at the source power generator, in the absence ofstabilization. FIG. 17D depicts the waveform of the stabilization VHFpower obtained using the synchronization follower 162 of the embodimentof FIG. 14, which more accurately follows the exponential response ofthe plasma electron density of FIG. 17B. FIG. 17E depict the reducedfluctuations in plasma electron density obtained using the stabilizationRF power of FIG. 17D. FIG. 17F depicts the reduced fluctuations inreflected power at the source power generator.

While the foregoing is directed to embodiments of the present invention,other and further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

1. A plasma reactor including a chamber for processing a workpiece,comprising: plural impedance matches and plural RF plasma powergenerators coupled to deliver respective RF plasma powers into saidchamber through respective ones of said impedance matches; a controllerfor generating a time-varying modulation control signal corresponding toa desired process transient cycle and an amplitude modulator coupled tomodulate the output of a first one of said generators in response tosaid time-varying modulation control signal; and a follower modulatorcoupled to modulate the output of a second one of said generators inresponse to said time-varying modulation control signal; wherein: saidfirst generator provides a signal representing a measured level of RFpower reflected back to the first generator, said signal being coupledto said controller; and said controller being programmed to alter thedegree of modulation of said second generator to minimize said measuredlevel of RF power reflected back to said first generator.
 2. The reactorof claim 1 wherein said first generator is an RF plasma source powergenerator, and wherein second generator is an RF bias power generatorhaving a frequency at which over 80% of RF power contributes to plasmasheath thickness.
 3. The reactor of claim 2 wherein said frequency ofsaid RF bias power generator is in or below an LF frequency range. 4.The reactor of claim 1 wherein said follower modulator comprises an R-Ccircuit for imposing a delay in the output of said second generatorrelative to said control signal.
 5. The reactor of claim 1 wherein saidcontrol signal corresponds to a transient that is one of (a) rectangularwave pulsing, (b) triangular wave.
 6. A plasma reactor including achamber with gas distribution apparatus for processing a workpiece,comprising: an RF plasma source power applicator; a source powerimpedance match and an RF plasma source power generator coupled to saidRF plasma source power applicator through said source power impedancematch; a controller for providing a time-varying modulation controlsignal corresponding to a desired process transient cycle and anamplitude modulator coupled to modulate the output of said source powergenerator in response to said time-varying modulation control signal;and an RF bias power generator operatively coupled to deliver RF biaspower to said workpiece, and a follower modulator coupled to modulatethe output of said RF bias power generator in response to saidtime-varying modulation control signal; wherein: said RF bias powergenerator has a frequency at which over 80% of RF power contributes toplasma sheath thickness; said source power generator provides a signalrepresenting a measured level of RF power reflected back to the sourcepower generator, said signal being coupled to said controller; and saidcontroller being programmed to alter the degree of modulation of saidbias power generator to minimize said measured level of RF powerreflected back to said generator.
 7. The reactor of claim 6 wherein saidfrequency of said RF bias power generator is in or below the LFfrequency range.
 8. The reactor of claim 6 wherein said followermodulator comprises an R-C circuit for imposing a delay in themodulation of said RF bias power generator relative to said controlsignal.